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Work experience

Self-Employed Mechanical Design Engineer in Industrial Automation

www.nailyusupov.com  |  Antalya, Türkiye |  Feb 2023 - Present

 

Services:

  • Conducting assessments of automation potential for existing or planned production sites, developing project plans and recommendations, and selecting appropriate technological equipment.

  • Auditing existing automated systems and developing modernization plans.

  • Designing custom equipment for automating production processes, including robotic end-effectors and specialized tooling.

  • Developing optimization projects for existing equipment.

  • Performing engineering calculations (strength, rigidity, vibration resistance, and durability).

  • Creating technical documentation, schematics, and user manuals.

FORCUS LLC | www.forcus.ru | Ufa, Russia

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Certified KUKA Robot Integrator.

Integration of industrial robots. Conveyor systems design and manufacturing.​

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Co-Founder, Chief Technical Officer | Mar 2018 – Jan 2023

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Key Responsibilities

  • Oversight of the company’s technical development, project direction, and establishment of core principles for new product design.

  • Leadership of a team of design engineers, including planning and supervision of the creation of new products, assemblies, and mechanisms (including critical, complex components).

  • Introduction and refinement of manufacturing and assembly technologies, equipment selection, and management of production processes.

  • Handling of HR functions, including recruitment, onboarding, and allocation of both engineering and production personnel.

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Achievements

  • Together with the other two co-founders, grew the company from a startup into a certified KUKA industrial robot integrator with a dedicated technical base, equipment, and a team of 13 employees.

  • Executed a full project cycle (design, development, manufacturing, and commissioning) for six robotic technology complexes. Integrated 10 industrial robots, replacing manual labor at over 80 workstations.

  • Developed and manufactured more than 20 types of conveyors and specialized transport systems.

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Production Challenges Solved

  • Established and launched a powder coating line; developed and optimized its process flow.

  • Procured and commissioned a 1.5 kW laser cutting machine and a 100-ton bending machine; optimized bending technology.

  • Created and implemented a business process for designing and purchasing components.

  • Standardized production workflows from documentation to assembly and final shipment.

DI ROBOTICS LLC | www.dirobotics.ru | Ufa, Russia

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Strategic Partner of FANUC in Russia. Integration of industrial robots. Robotic solutions for palletizing and packaging processes.

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Chief Engineer, Head of Design Department | Jun 2017 – Mar 2018

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Key Responsibilities

  • Leadership of a team of design engineers.

  • Technical assessment of automation targets, including production areas, workshops, and machines, and development of automation concepts and multiple project architecture options.

  • Design of complex and critical components.

  • Support for manufacturing, assembly, commissioning, and startup processes.

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Achievements

  • Successfully completed the design, production support, and launch of seven automation and robotics projects across various industries and applications within a short time frame, including:

    • Robotic machine tending for handling long workpieces up to 8 meters.

    • Robotic palletizing operations.

    • Robotic primary packaging of food products.

    • Robotic assembly processes.

    • Automated inter-departmental transportation of workpieces.

    • Robotic defect detection in X-ray exposure zones.

AVIATECH LLC | www.aviateh.com | Ufa, Russia

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Certified KUKA Robot Integrator. FANUC and ABB Robot Integrator.

Integration of industrial robots. Solutions for automating complex production processes.

 

Head of Design and Technology Department | Jan 2016 – Jun 2017

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Key Responsibilities

  • Organization and management of a team of design engineers and technologists, including resource planning and project timeline estimation.

  • Technical evaluation of automation objects, assessment of project timelines, and determination of equipment development complexity during the contract phase.

  • Selection and support of procurement for specialized technological equipment.

  • Design of complex and critical components.

  • Support for production, assembly, and commissioning processes.

  • Review of graduation projects by "Mechatronics" students at Ufa State Aviation Technical University.

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Achievements

  • Successfully implemented a PDM system, creating a comprehensive database of models and design documentation for projects.

  • Streamlined and formalized communication processes between the design and technology department and other departments (procurement, programming and electronics, assembly) as well as project managers.

  • Delivered successful robotics projects, including:

    • High-speed perforation of composite materials.

    • Robotic trimming of gating systems for large magnesium alloy parts.

    • Contour trimming of polymer components for automotive manufacturers (bus and truck assembly plants).

    • Palletizing boxes of agricultural chemicals.

    • Packaging of pharmaceutical products in a closed robotic cell meeting pharmaceutical industry standards.

    • Machining of polymer parts for optical systems production.

    • Painting of dump truck bodies.

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Design Engineer | Jan 2013 – Jan 2016

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Key Responsibilities

  • Development of special equipment for robotic systems and cells.

  • Author’s supervision of the manufacturing process for designed components.

  • Design of layout solutions for robotic systems and definition of requirements for site and equipment preparations.

  • On-site visits for data collection, assembly oversight, and commissioning processes in special cases.

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Achievements

  • Successfully implemented robotic automation projects for the following technological processes:

    • Welding of large-sized parts on a tilting rotary positioner (work table 8 x 4 meters).

    • Welding of small- and medium-sized parts using robotic cells with tooling based on modular fixtures.

    • Machining of granite for the production of granite sculptures.

    • Waterjet cutting of composite materials (nozzle mounted on a robot) and waterjet trimming of gating systems (stationary nozzle with robot handling).

    • Robotic adaptive grinding of turbine blades.

    • Automation of optical device testing (development of a laboratory stand with a working area of 4 x 2 meters).

    • Robotic adhesive application on automobile glass before bonding.

    • Welding of helicopter gearbox mounting components with spatial tooling.

    • Welding of transformer tanks.

ECM LLC | www.indec-ecm.com | Ufa, Russia

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Technologies and equipment for high-precision electrochemical machining.

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Design Engineer | Jan 2012 – Jan 2013

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Key Responsibilities

  • Design of components and mechatronic modules for electrochemical machines, both independently and as part of a team, including management of the complete design process for specialized machine systems.​

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Achievements

  • Developed a circular feed drive and support system for a special machine used in processing large-diameter, extremely thin-walled titanium cylindrical blanks. The system operated within an electrolyte bath, featured a high-precision motorized rotation mechanism, and provided excellent positioning accuracy.

  • Designed a working chamber for a multi-positional electrochemical machine with two degrees of freedom, intended for high-precision processing of gas turbine engine blades. The chamber was adaptable for blades at various angles and accommodated over 100 cables (10 mm in diameter) within its working zone. It ensured precise electrolyte level control, forced ventilation with protection against electrolyte splashes, and simple adjustments for processing blades at different angles.

 

BURSERVICE JSC | www.burservice.ru | Ufa, Russia

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Development and manufacturing of mining tools for the oil and gas industry.

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Process Engineer | Jun 2011 – Jan 2012

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Key Responsibilities

  • Development and implementation of machining processes for universal and CNC machines, as well as welding and surfacing processes.

  • Design and deployment of tooling for new products, ensuring compatibility with advanced machining equipment.

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Achievements

  • Machining technology for several products was transferred from universal machines to a new five-axis CNC machine, ensuring a seamless transition and enhanced production capabilities.

  • A methodology for comparative evaluation of tools was developed, the supplier was selected, and optimal cutting parameters were determined, reducing tooling costs.

  • Promoted to Design Engineer based on demonstrated competence and effective contributions to process improvement and tooling design.

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